ARRANGEMENT COMPRISING A SHUNT RESISTOR AND METHOD FOR PRODUCING AN ARRANGEMENT COMPRISING A SHUNT RESISTOR
The invention relates to an arrangement comprising a shunt resistor with at least an electrically conductive first connecting leg and an electrically conductive second connecting leg. A resistance area of the shunt resistor is electrically connected to the first connecting leg and to the second connecting leg. The arrangement further comprises a circuit carrier with a first metallization and a second metallization. The first connecting leg is directly joined to the first metallization and the second connecting leg is directly joined to the second metallization. The resistance area of the shunt resistor is in thermal contact with the thermally conductive substrate by use of a thermal filler arranged between the resistance area and the substrate, and/or by directly contacting the resistance area with the substrate. The invention further relates to a method for producing an arrangement with a shunt resistor and a circuit carrier.
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The invention relates to arrangements comprising a shunt resistor.
BACKGROUNDShunt resistors are used to precisely determine electric currents, e.g. in power semiconductor modules. Conventional shunt resistors extend over a large area and are electrically connected, e.g., to a circuit carrier, by soldering. Physically, two conflicting properties are requested. First is a rather large electrical resistance to enable accurate current measurements. Second is a low thermal resistance to avoid overheating through the dissipated power. Since both properties do not combine well, shunt resistors usually heat up to high temperatures and therefore a degradation of the solder and, coming along therewith, delamination of the shunt resistor may arise. This is one of the reasons why shunt resistors generally are specified to certain maximum temperatures, e.g. 250° C.
SUMMARYThe present invention relates to an arrangement comprising a shunt resistor with at least an electrically conductive first connecting leg an electrically conductive second connecting legs and a resistance area. The resistance area is electrically connected to the first connecting leg and to the second connecting leg. The arrangement further comprises a circuit carrier with a first metallization and a second metallization. The first connecting leg is joined to the first metallization and the second connecting leg is joined to the second metallization. According to a first aspect of the invention, a cooling path from the resistance area to the circuit carrier is created. The cooling path may be realized by a heat conductive filler which is arranged between the circuit carrier and the resistance area. Just as well, the cooling path may be realized by a direct contact between the resistance area and the circuit carrier.
The invention further relates to a method for joining a shunt resistor and a circuit carrier. In the method, a shunt resistor comprising at least an electrically conductive first connecting leg, an electrically conductive second connecting leg, and a resistance area arranged between and electrically connected to the first connecting leg and the second connecting leg, are provided. Further, a circuit carrier comprising a first metallization and a second metallization is provided. The shunt resistor is positioned on the circuit carrier such that the first connecting leg is in contact with the first metallization and that the second connecting leg is in contact with the second metallization. Then, the first connecting leg is joined with the first metallization and the second connecting leg is joined with the second metallization by use of an ultrasonic bonding technique.
The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, instead emphasis being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts. In the drawings:
If an electric current flows between the first connecting leg 11 and the second connecting leg 12 the current has to pass the resistance area 15. This will cause a voltage drop that may be measured whit a high-impedance voltage measuring device connected to the third connecting leg 13 and the fourth connecting leg 14. From the measured voltage and the known resistance of the resistance area 15 the electric current through the resistance area may be calculated precisely.
The first connecting leg 11 may be directly ultrasonic bonded to the first metallization 51, the second connecting leg 12 may be directly ultrasonic bonded to the second metallization 52. “Directly” means that no other material is arranged between the connecting legs 11, 12 and the respective metallization 51 and 52, respectively. However, instead of a single layer only, the metallization 51, 52 may alternatively be designed as multilayer metallization comprising at least two sub-metallization layers. In the case of a shunt resistor 10 additionally comprising third and fourth connecting legs 13, 14, respectively, the additional legs 13, 14 may also be ultrasonic bonded directly to respective metallizations.
In
As shown in
λ=(ΔP·d)/(ΔT·A) (1)
As an example, removing 30% of a dissipated power of 8 W within a resistive area A of 25 mm2, located 1 mm above the substrate with ΔT of 100 K requires λ=0.96 W·K−1·m−1.
If the heat conductive filler 30 is a dielectric, it may directly contact with the shunt resistor 30 and the metallizations 51, 52 without affecting the result of the resistance measurement. However, in case of an electrically conductively filler 30, insulation measures between the filler 30 and the metallizations 51, 52 and between the filler 30 and the resistance area 15 are required. In this case the filler's thermal conductivity λ according to eq. (1) must be calculated as an effective value of insulation and filler material.
A suitable material to be used as heat conductive filler 30 is, for example, ceramic material. The filler may consist of ceramic material or comprise at least 50% by weight of ceramic material.
In the arrangement shown in
In a further step, the shunt resistor 10 is placed on the circuit carrier 50 such that the flange 11a of the first connecting leg 11 is arranged on the first metallization 51 and the flange 12a of the second connecting leg 12 is arranged on the second metallization 52. Optionally, the shunt resistor 10 is positioned on the circuit carrier 50 such that the flange 11a directly contacts with the first metallization 51 and that the flange 12a directly contacts with the second metallization 52. Alternative to a direct contact between the flanges 11a, 12a and a respective metallization 51, 52, at least one of the flanges 11a, 12a may remain distant from the metallization 51, 52 to which it is to be bonded.
Then, a sonotrode 80 applies a down force F to the connecting legs 11 and 12, e.g. to the flanges 11a, 12b thereof, and the shunt resistor 10 is pressed against the circuit carrier 50. Additionally to the down force F, the sonotrode provides ultrasonic waves which are transmitted to the flanges 11a and 12a which effects a strong joint between the connecting legs 11 and 12 and the respective metallizations 51, 52. As the sonotrode 80 is bifurcated and comprises two legs 81 and 82, the shunt resistor 10 may be ultrasonic bonded to the substrate 50 simultaneously in one bonding step.
In case of a shunt resistor 10 comprising more than two connecting legs 11, 12, the additional legs (see, e.g., the third and fourth connecting legs 13, 14 in
After finishing the bonding process and after removing the sonotrode 80, the area between the circuit carrier 50 and the resistance area 15 may be filled with a heat conductive filler 30. For example, as filler 30 a ceramic paste comprising ceramic powder may be filled in under the resistance area 15.
In the example of
In a first step shown in
Then, as shown in
In a further step shown in
As shown in
In the example of
In the arrangement of
In the arrangement shown in
Such a shunt resistor 10 is shown in
In the previous examples, a circuit carrier 50 based on a dielectric ceramic substrate 56 has been described. However, the present invention also refers any other circuit carrier 50 comprising metallizations 51, 52. For example, a circuit carrier 50 may be formed as insulated metal substrate (IMS substrate). An example of such a circuit carrier 50 based on IMS technology is shown in
As described above, one aspect of the present invention is to simultaneously join two or more connecting legs of a shunt resistor to a circuit carrier by use of a bifurcated sonotrode. This technique may also apply to arrangements, in which a shunt resistor is bonded to a circuit carrier without a heat conductive filler arranged between the resistance area and the circuit carrier, and without the resistance area directly contacting with the circuit carrier. Further, instead of a joint formation by ultrasonic bonding the arrangements described above could also be manufactured by ultrasonic welding technique, by HF-welding technique, by laser welding technique, by spot welding technique, or by rotary friction welding technique.
Although various examples to realize the invention have been disclosed, it will be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the spirit and scope of the invention. It will be obvious to those reasonably skilled in the art that other components performing the same functions may be suitably substituted. Such modifications to the inventive concept are intended to be covered by the appended claims.
Claims
1. An arrangement comprising:
- a shunt resistor comprising at least an electrically conductive first connecting leg, an electrically conductive second connecting leg, and a resistance area electrically connected to the first connecting leg and to the second connecting leg;
- a circuit carrier comprising a first metallization and a second metallization; where
- the first connecting leg is joined to the first metallization and the second connecting leg is joined to the second metallization; and
- where the resistance area directly contacts with the circuit carrier and/or where a heat conductive filler is arranged between the circuit carrier and the resistance area.
2. The arrangement of claim 1 where a heat conductive filler arranged between the circuit carrier and the resistance area contacts with the circuit carrier.
3. The arrangement of claim 1 where a heat conductive filler arranged between the circuit carrier and the resistance area contacts with the resistance area.
4. The arrangement of claim 1 where a heat conductive filler arranged between the circuit carrier and the resistance area comprises a thermal conductivity of greater than 1 W·K−1·m−1.
5. The arrangement of claim 1 where a heat conductive filler arranged between the circuit carrier and the resistance area consists of ceramic material or comprises at least 50% by weight of ceramic material.
6. The arrangement of claim 1 where the resistance area is pressed against the circuit carrier by the effect of a spring tension of at least one of the first connecting and the second connecting legs.
7. The arrangement of claim 1 where the circuit carrier comprises a substrate made of ceramic material.
8. The arrangement of claim 1 where the circuit carrier comprises an isolated metal substrate (IMS).
9. The arrangement of claim 1 where the first connecting leg is directly joined to the first metallization and/or where the second connecting leg is directly joined to the second metallization.
10. An arrangement comprising:
- a shunt resistor comprising at least an electrically conductive first connecting leg, an electrically conductive second connecting leg, and a resistance area electrically connected to the first connecting leg and to the second connecting leg;
- a circuit carrier comprising a first metallization and a second metallization; where
- the first connecting leg is directly joined to the first metallization and the second connecting leg is directly joined to the second metallization.
- a first bonding area arranged between the first connecting leg and the resistance area.
11. The arrangement of claim 10 comprising a first bonding wire which is bonded to a third metallization of the circuit carrier and to the first bonding area.
12. The arrangement of claim 10 where the first bonding area is formed by a plane surface section of the first connecting leg.
13. The arrangement of claim 12 where the plane surface section of the first connecting leg runs parallel to the circuit carrier.
14. The arrangement of claim 12 where the plane surface section of the first connecting leg comprises an area ranging from 0.1 mm×0.1 mm to 0.8 mm to 2.0 mm.
15. The arrangement of claim 11 comprising a second bonding area arranged between the second connecting leg and the resistance area.
16. The arrangement of claim 15 comprising a second bonding wire which is bonded to a fourth metallization of the circuit carrier and to the second bonding area.
17. The arrangement of claim 15 where the second bonding area is formed by a plane surface section of the second connecting leg.
18. The arrangement of claim 12 where the plane surface section of the second connecting leg runs parallel to the circuit carrier.
19. The arrangement of claim 17 where the plane surface section of the second connecting leg comprises an area ranging from 0.1 mm×0.1 mm to 0.8 mm to 2.0 mm.
20. A method for joining a shunt resistor and a circuit carrier, the method comprising the steps:
- providing a shunt resistor comprising at least an electrically conductive first connecting leg, an electrically conductive second connecting leg, and a resistance area electrically connected to the first connecting leg and to the second connecting leg;
- providing a circuit carrier comprising a first metallization and a second metallization;
- positioning the shunt resistor on the circuit carrier such that the first connecting leg contacts with the first metallization and that the second connecting leg contacts with the second metallization;
- joining the first connecting leg with the first metallization and joining the second connecting leg with the second metallization by use of an ultrasonic bonding technique.
21. The method of claim 20 where the step of joining comprises the sub step of providing a bifurcated sonotrode.
22. The method of claim 20 where joining the first connecting leg with the first metallization and joining the second connecting leg with the second metallization by use of an ultrasonic bonding technique takes place simultaneously.
23. The method of claim 20 comprising the step of providing a heat conductive filler and arranging the heat conductive filler between the circuit carrier and the resistance area.
24. The method of claim 23 where the step of arranging the heat conductive filler takes place prior to the step of joining the first connecting leg with the first metallization and joining the second connecting leg.
25. The method of claim 23 where the step of arranging the heat conductive filler takes place after the step of joining the first connecting leg with the first metallization and joining the second connecting leg.
26. The method of claim 18 where the heat conductive filler comprises a thermal conductivity of greater than 1 W·K−1·m−1.
27. The method of claim 20 where the resistance area is directly contacted with the circuit carrier.
28. The method of claim 20 where a down force is applied to at least one section of at least one of the first connecting leg and the second connecting leg, where, when the down force starts to affect the at least one section, the at least one section is distant from the circuit carrier.
29. The method of claim 28 where, after joining the first connecting leg with the first metallization and after joining the second connecting leg with the second metallization, the at least one section completely contacts with the first or second metallization.
Type: Application
Filed: Jan 8, 2008
Publication Date: Jul 9, 2009
Patent Grant number: 8031043
Applicant: INFINEON TECHNOLOGIES AG (Neubiberg)
Inventors: Martin Schulz (Erwitte), Peter Kanschat (Soest)
Application Number: 11/970,661